KSB COBRA-TDC01/03 Installation instructions

Tilting Disc Check Valve
COBRA-TDC01/03
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual COBRA-TDC01/03
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 18/08/2022

Contents
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Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Target group.....................................................................................................................................................6
1.3 Other applicable documents............................................................................................................................6
1.4 Symbols .............................................................................................................................................................6
1.5 Key to safety symbols/markings.......................................................................................................................7
2 Safety...................................................................................................................................................... 8
2.1 General..............................................................................................................................................................8
2.2 Intended use .....................................................................................................................................................8
2.2.1 Prevention of foreseeable misuse.......................................................................................................9
2.3 Personnel qualification and training...............................................................................................................9
2.4 Consequences and risks caused by non-compliance with this manual .........................................................9
2.5 Safety awareness ..............................................................................................................................................9
2.6 Safety information for the operator/user.......................................................................................................9
2.7 Safety information for maintenance, inspection and installation ..............................................................10
2.8 Unauthorised modes of operation................................................................................................................10
3 Transport/Storage/Disposal ................................................................................................................ 11
3.1 Checking the condition upon delivery..........................................................................................................11
3.2 Transport.........................................................................................................................................................11
3.3 Storage/preservation......................................................................................................................................11
3.4 Return to supplier...........................................................................................................................................12
3.5 Disposal ...........................................................................................................................................................12
4 Description of the valve ...................................................................................................................... 13
4.1 General description ........................................................................................................................................13
4.2 Product information.......................................................................................................................................13
4.2.1 EC Machinery Directive 2006/42/EC...................................................................................................13
4.2.2 Product information as per Regulation No. 1907/2006(REACH) ....................................................13
4.3 Marking...........................................................................................................................................................13
4.4 Design details..................................................................................................................................................13
4.5 Function ..........................................................................................................................................................14
4.6 Scope of supply...............................................................................................................................................14
4.7 Noise characteristic.........................................................................................................................................14
5 Installation at Site................................................................................................................................ 15
5.1 General information/Safety regulations .......................................................................................................15
5.2 Installation position........................................................................................................................................15
5.3 Preparing the valve ........................................................................................................................................16
5.4 Piping ..............................................................................................................................................................16
5.4.1 Flange connection..............................................................................................................................17
5.5 Insulation ........................................................................................................................................................17
6 Commissioning/Start-up/Shutdown................................................................................................... 18
6.1 Commissioning................................................................................................................................................18
6.1.1 Prerequisites for commissioning/start-up .........................................................................................18
6.1.2 Functional test....................................................................................................................................18
6.2 Operating limits..............................................................................................................................................18
6.2.1 Pressure/temperature ratings............................................................................................................19
6.2.2 Flow velocity.......................................................................................................................................19
6.3 Shutdown........................................................................................................................................................20
6.3.1 Measures to be taken for shutdown ................................................................................................20
6.4 Returning to service .......................................................................................................................................20

Contents
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7 Servicing/Maintenance........................................................................................................................ 21
7.1 Safety regulations...........................................................................................................................................21
7.2 Servicing/Inspection........................................................................................................................................21
7.2.1 Supervision of operation ...................................................................................................................21
7.2.2 Inspection work..................................................................................................................................22
7.2.3 Dismantling the valve ........................................................................................................................22
7.2.4 Assembling the valve .........................................................................................................................23
7.2.5 Tightening torques ............................................................................................................................24
8 Trouble-shooting.................................................................................................................................. 25
9 Related Documents.............................................................................................................................. 26
9.1 General assembly drawing with list of components COBRA-TDC01 ...........................................................26
9.2 General assembly drawing with list of components COBRA-TDC03 ...........................................................27
Index ..................................................................................................................................................... 29

Glossary
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Glossary
PN
Nominal pressure; a characteristic upon which
standards regarding piping, piping components,
valves, etc., are based

1 General
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1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The operating manual describes the proper and safe use of this equipment in all
phases of operation.
The name plate indicates the type series, the main operating data and the serial
number. The serial number uniquely describes the product and is used as
identification in all further business processes.
In the event of damage, immediately contact your nearest sales organisation
responsible to maintain the right to claim under warranty.
1.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.
1.3 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Type series booklet Description of the valve
General assembly drawing1) Sectional drawing of the valve
Sub-supplier product literature Operating manuals and other product literature
describing accessories and integrated machinery
components
For accessories and/or integrated machinery components, observe the relevant
manufacturer's product literature.
1.4 Symbols
Table2: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1If included in agreed scope of supply

1 General
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1.5 Key to safety symbols/markings
Table3: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.

2 Safety
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2 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
2.1 General
▪This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
▪Comply with all the safety instructions given in the individual sections of this
operating manual.
▪The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
▪The contents of this operating manual must be available to the specialist
personnel at the site at all times.
▪Information and markings attached directly to the product must always be
complied with and kept in a perfectly legible condition at all times. This applies
to, for example:
– Manufacturer
– Type designation
– Nominal pressure
– Nominal size
– Year of construction
– Valve body material
▪The operator is responsible for ensuring compliance with all local regulations not
taken into account.
▪The design, manufacture and testing of the valve are subject to a QM system to
DINENISO9001 as well as the current regulations and directives for pressure
equipment.
▪Bear in mind that valves exposed to creep-rupture conditions have a limited
service life and have to meet the applicable regulations stipulated in the
technical codes.
▪In the case of customised special variants, further restrictions may apply with
regard to the operating mode and service life. Refer to the relevant sales
documentation for applicable limitations.
▪The operator is responsible for ensuring compliance with all local regulations not
taken into account.
▪The operator is responsible for any eventualities or incidents which may occur
during installation performed by the customer, operation and maintenance.
2.2 Intended use
▪Only operate valves which are in perfect technical condition.
▪Do not operate the valve in partially assembled condition.
▪Only use the valve for fluids specified in the product literature. Take the design
and material variant into account.
▪Only operate the valve within the operating limits described in the other
applicable documents.
▪The valve's design and rating are based on predominantly static loading in
accordance with the codes applied. Consult the manufacturer if the valve is
subjected to dynamic loads or any other additional influences.
▪Consult the manufacturer about any other modes of operation not described in
the product literature.
▪Do not use the valve as a foothold.

2 Safety
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2.2.1 Prevention of foreseeable misuse
▪Never exceed the permissible application and operating limits specified in the
data sheet or product literature regarding temperature, etc.
▪Observe all safety information and instructions in this manual.
2.3 Personnel qualification and training
▪All personnel involved must be fully qualified to transport, install, operate,
maintain and inspect the product this manual refers to and be fully aware of the
interaction between the valve and the system.
▪The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
▪Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
▪Training on the valve must always be supervised by specialist technical personnel.
2.4 Consequences and risks caused by non-compliance with this manual
▪Non-compliance with these operating instructions will lead to forfeiture of
warranty cover and of any and all rights to claims for damages.
▪Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.5 Safety awareness
In addition to the safety information contained in this operating manual and the
intended use, the following safety regulations shall be complied with:
▪Accident prevention, health regulations and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws
2.6 Safety information for the operator/user
▪Fit protective equipment (e.g. contact guards) supplied by the operator for hot,
cold or moving parts, and check that the equipment functions properly.
▪Do not remove any protective equipment (e.g. contact guards) during operation.
▪Provide the personnel with protective equipment and make sure it is used.
▪Contain any leakage of hazardous fluids (e.g. explosive, toxic, hot) so as to avoid
any danger to persons and the environment. Adhere to all relevant laws.
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
▪Take protective measures against the impact of potentially occurring surge
pressure (e.g. bursting discs).

2 Safety
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2.7 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the valve require the manufacturer's prior
consent.
▪Use only original spare parts or parts/components authorised by the
manufacturer. The use of other parts/components can invalidate any liability of
the manufacturer for resulting damage.
▪The operator ensures that maintenance, inspection and installation are
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Carry out work on the valve during standstill only.
▪The valve body must have cooled down to ambient temperature.
▪The pressure in the valve body must have been released and the valve must have
been drained.
▪When taking the valve out of service always adhere to the procedure described
in the manual.
▪Decontaminate valves which handle fluids posing a health hazard.
▪Protect the valve body and body bonnet/cover from any impacts.
▪As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning.
2.8 Unauthorised modes of operation
▪The valve is operated outside the limits stated in the operating manual.
▪The valve is not operated in accordance with the intended use.
(ðSection2.2,Page8)

3 Transport/Storage/Disposal
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3 Transport/Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify or the supplying dealer and the insurer about the damage in writing
immediately.
3.2 Transport
DANGER
The valve could slip out of the suspension arrangement
Danger to life from falling parts!
▷Only transport the valve in the specified position.
▷Never attach lifting accessories to the handwheel or valve disc.
▷Observe the information on weights, centre of gravity and fastening points.
▷Observe the applicable local accident prevention regulations.
▷Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.
▷For valves with actuators observe the relevant actuator operating manual.
Transport aids on the actuator are not suitable for suspending the entire valve/
actuator assembly.
To transport the valve, suspend it from the lifting tackle as illustrated.
Fig.1: Transporting the valve
1. Suspend the valve from the lifting equipment and transport it.
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for storing the valve:

3 Transport/Storage/Disposal
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CAUTION
Damage due to frost, humidity or dirt
Corrosion/contamination of the valve!
▷Store the valve in a dry, dust-free and vibration-free, frost-proof room where
the atmospheric humidity is as constant as possible.
▷Protect the valve against contamination, e.g. with suitable caps or film.
CAUTION
Damage due to excessive valve closure
Damage to the seat/disc interface!
▷Store the valve with the valve disc at 5° from the closed position.
Storage and/or temporary storage of the valves must ensure that even after a
prolonged period of storage the valves’ function is not impaired.
The temperature at the storage location must be between +5°C and +50°C.
Protect the sealing elements (elastomers) from sunlight or UV light from other
sources. Observe the DIN7716 standard when storing elastomers.
Cover the counterweight or hydraulic damper to protect against dust, dirt and
mechanical damage.
If properly stored indoors, the equipment is protected for a maximum of 12months.
New valves are delivered duly prepared for storage.
For storing a valve which has already been operated, observe the measures to be
taken for shutdown. (ðSection6.3,Page20)
3.4 Return to supplier
1. Drain the valve as described in the manual.
2. Flush and clean the valve, particularly if it has been used for handling noxious,
explosive, hot or other hazardous fluids.
3. If the valve has handled fluids whose residues could lead to corrosion damage in
the presence of atmospheric humidity or could ignite upon contact with oxygen
also neutralise the valve and blow through with anhydrous inert gas to ensure
drying.
3.5 Disposal
WARNING
Fluids handled, consumables and supplies which are hot or pose a health hazard
Hazard to persons and the environment!
▷Collect and properly dispose of flushing fluid and any residues of the fluid
handled.
▷Wear safety clothing and a protective mask if required.
▷Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Dismantle the valve.
Collect greases and other lubricants during dismantling.
2. Separate and sort the valve materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another
controlled manner.

4 Description of the valve
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4 Description of the valve
4.1 General description
▪Tilting disc check valve with epoxy coating
Valve for preventing flow reversal in irrigation systems, cooling circuits, water
treatment systems and water supply systems.
4.2 Product information
4.2.1 EC Machinery Directive 2006/42/EC
The valve meets the fundamental safety requirements as per EC Machinery Directive
2006/42/EC, Annex1.
4.2.2 Product information as per Regulation No. 1907/2006(REACH)
For information as per chemicals Regulation (EC) No. 1907/2006 (REACH), see https://
www.ksb.com/ksb-en/About-KSB/Corporate-responsibility/reach/ .
4.3 Marking
Table4: General marking
Description Marking
Nominal size DN ...
Nominal pressure class PN ...
Manufacturer KSB
Type series/Model COBRA-TDC..
Material .......
Flow direction arrow →
4.4 Design details
Design
▪Design in accordance with EN 16767
▪Double-flanged body with short face-to-face length to EN558/14
▪Flanged ends to DIN EN 1092-2:
PN 10 ≤ DN 1400
PN 16 ≤ DN 1400
PN 25 ≤ DN 1000
PN 40 ≤ DN 1000
▪Marked in accordance with DINEN19 (ISO5209)
▪Counterweight for horizontal installation
▪With counterweight, or with counterweight with hydraulic damper
▪Epoxy-coated body
▪Valve certified for drinking water applications to WRAS (elastomer and coating)
Variants
▪Smaller nominal sizes from DN 80 (only after technical evaluation)
▪NBR gasket
▪Counterweight for vertical installation

4 Description of the valve
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4.5 Function
Design The tilting disc check valve comprises the pressure-retaining parts, i.e. the body, the
actuating shaft, the functional unit (shaft and valve disc) and the elastomer ring on
the valve disc.
Function The valve is opened by the pressure inside the pipe and closed by back pressure of
the counterweight.
Sealing The valve disc and actuating shaft are joined by keys and sealed to atmosphere by O-
rings.
4.6 Scope of supply
The following items are included in the scope of supply:
▪Valve
▪Valve operating manual
4.7 Noise characteristic
When operated within the operating conditions documented in the order
confirmation and/or characteristic curves booklets, the valve will not exceed a sound
pressure level of 80dB in acc. with IEC60534-8-4. Unfavourable piping layouts or off-
design operating conditions may give rise to physical phenomena like cavitation,
resulting in significantly higher sound pressure levels.

5 Installation at Site
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5 Installation at Site
5.1 General information/Safety regulations
The consultant, construction company or operator are responsible for positioning
and installing the valves. Planning errors and installation errors may impair the
reliable function of the valves and pose a substantial safety hazard.
WARNING
Damage to pressure enclosure or add-on parts
Leakage from or rupture of the valve
Valve/add-on parts not functional
▷Check the valve for in-transit damage prior to installation.
▷Check any add-on parts for in-transit damage.
▷Do not install damaged valves.
5.2 Installation position
The valves should preferably be installed in horizontal pipes. When installing them in
vertical pipes, make sure that the flow direction is upward. In the unpressurised
condition, the valve disc will then be closed by its own weight.
Fig.2: Vertical and horizontal installation position of COBRA-TDC01/03
DANGER
Dead-end valve
High-pressure hazard!
Risk of burns!
▷Protect the valve against unauthorised and/or unintentional opening.

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Recommended upstream and downstream stabilisation distances
Fig.3: Recommended minimum distance between the valve and a tee or elbow
Upstream and downstream stabilisation distances are also required for valves
installed on the pump discharge side.
Installation downstream of control valves, a plunger valve or a flow meter
Observe a minimum distance of 10 times the nominal size.
5.3 Preparing the valve
CAUTION
Outdoor installation
Damage due to corrosion!
▷Provide weather-proof protection to protect the valve against moisture.
1. Thoroughly clean, flush and blow through all vessels, piping and connections.
2. Remove the valve's flange covers before installing it in the piping.
3. Check that the inside of the valve is free from any foreign objects. Remove any
foreign objects.
4. If required, install a strainer in the piping.
5.4 Piping
WARNING
Impermissible piping forces
Leakage from or rupture of the valve body!
▷Connect the pipes to the valve without transmitting any stresses or strains.
▷Take structural measures to prevent any piping forces from being transmitted
to the valve.
▷Avoid mechanical loads beyond normal levels, e.g. piping forces, moments and
vibrations.

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CAUTION
Painting pipes and actuator
Valve function impaired!
▷Protect stem, plastic components and actuator elements prior to applying paint.
▪For any further work (e.g. construction work, cleaning measures) protect the
valve and the piping against contamination (e.g. by covering it with a tarpaulin).
5.4.1 Flange connection
Fasteners Always use all flange bolt holes provided when connecting the valve to the pipe.
Flange connection üThe mating flange faces are clean and undamaged.
üVerify that the pipe is correctly aligned and the flanges are parallel.
üThe inside diameter of the pipe flanges is within the permissible minimum and
maximum diameter limits.
üOpen and close the valve to check that the valve disc rotates freely.
1. Move the valve to the open position. Open it as far as possible without the valve
disc protruding beyond the body.
2. Push the pipe flanges as far apart as required to achieve a sufficient clearance
between the flange gaskets and the protruding liner faces.
3. Insert the valve between the two flanges and centre it with fasteners.
4. Tighten the fasteners evenly and crosswise with a suitable tool until contact is
established between the body and the pipe flanges.
5. Actuate the valve several times to verify that the valve disc rotates freely.
5.5 Insulation
WARNING
Cold/hot piping and/or valve
Risk of thermal injury!
▷Insulate the valve.
▷Fit warning signs.
For any insulation fitted on the valve observe the following:
▪The valve's function must not be impaired.

6 Commissioning/Start-up/Shutdown
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6 Commissioning/Start-up/Shutdown
6.1 Commissioning
CAUTION
Welding beads, scale and other impurities in the piping
Damage to the valve!
▷Remove any impurities from the piping, e.g. by flushing the pipe with the valve
in fully open position.
▷If necessary, install a strainer.
6.1.1 Prerequisites for commissioning/start-up
DANGER
Surge pressure/water hammer potentially occurring at high temperatures
Danger to life caused by burns or scalds!
▷Do not exceed the valve's maximum permissible pressure.
▷Use valves made of nodular cast iron or steel.
▷The operator shall provide general safety measures for the system.
Before commissioning/start-up of the valve ensure that the following requirements
are met:
▪The valve has been connected to the piping at both ends.
▪The shut-off function of the installed valve has been checked by opening and
closing it several times.
▪The piping has been flushed.
▪The material, pressure data and temperature data of the valve are compatible
with the operating conditions of the piping. (ðSection6.2,Page18)
▪The material's chemical resistance and stability under load have been checked.
6.1.2 Functional test
The following functions must be checked:
1. Check the shut-off function of the installed valve prior to commissioning/start-
up by opening and closing the valve several times.
6.2 Operating limits

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6.2.1 Pressure/temperature ratings
Table5: Permissible operating pressure [bar]
PN Material [°C]
-10 to 120 150 200 250 300 350
10 EN-GJS-400-15 10 9,7 9,2 8,7 8 7
16 16 15,5 14,7 13,9 12,8 11,2
25 25 24,3 23 21,8 20 17,5
40 40 38,8 36,8 34,8 32 28
6.2.2 Flow velocity
Table6: Permissible flow velocity with the valve fully open
PN [m/s]
10 3,0
16 4,0
25 5,0
40 6,0

6 Commissioning/Start-up/Shutdown
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6.3 Shutdown
6.3.1 Measures to be taken for shutdown
During prolonged shutdown periods, ensure that the following conditions are met:
1. Drain fluids which change their physical condition due to changes in
concentration, polymerisation, crystallisation, solidification, etc. from the piping.
2. If required, flush the piping with the valves fully opened.
6.3.1.1 Valve with handwheel
1. Close the valve by turning the handwheel in clockwise direction.
6.4 Returning to service
For returning the equipment to service, observe the sections on commissioning/start-
up and the operating limits (ðSection6.2,Page18) .
In addition, carry out all servicing/maintenance operations before returning the valve
to service. (ðSection7,Page21)